ZKA-TI-16_17MY P
Service Bulletin Details
Public Details for: ZKA-TI-16_17MY P
Technical instructions for warranty enhancement program zka certain 2016 through 2017 model year tacoma
Models from 2017
| 2017 TOYOTA TACOMA |
Models from 2016
| 2016 TOYOTA TACOMA |
TECHNICAL INSTRUCTIONS FOR WARRANTY ENHANCEMENT PROGRAM ZKA ***************************** CERTAIN 2016 THROUGH 2017 MODEL YEAR TACOMA ***************************** FRAME REPLACEMENT The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this CSP are required to successfully complete the most current version of the E-Learning course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly; technicians performing this repair are required to currently hold at least one of the following certification levels: • • • • Certified Technician (any specialty) Expert Technician (any specialty) Master Technician Master Diagnostic Technician Final repair must be signed off and validated by a MDT, Shop Foreman or Service Manager using the Frame Replacement Inspection Form. It is the dealership’s responsibility to select technicians with the above certification level or greater to perform this CSP repair. Carefully review your resources, the technician skill level, and ability before assigning technicians to this repair. It is important to consider technician days off and vacation schedules to ensure there are properly trained technicians available to perform this repair at all times. 1 OPERATION FLOWCHART Verify Vehicle Eligibility 1. Confirm vehicle VIN matches the R.O. 2. Check the TIS Vehicle Inquiry System Not Covered No further action required Frame Rail Seal ALREADY INSTALLED No further action required Covered Perform pre-hoist inspection Inspect for Frame Rail Seal Frame Rail Seal NOT FOUND Please see to the K0D Technical Instructions and Dealer Letter for the next steps Perform Frame Inspection utilizing the Inspection application Yes (to either question) Was perforation 10mm or larger found in the locations identified in Green below? No Are you located in a Cold Climate State, or is the vehicle eligible for K0D? No (to both questions) Yes Inspection Application submits report for FTS approval No No further action required Was approval received from the FTS? Yes Order parts and complete frame replacement Campaign completed, return the vehicle to the customer Cold Climate States Include - CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, WV and District of Columbia Background Toyota has received a number of reports regarding vehicle frame corrosion perforation on certain 2011-2017 model year Tacoma vehicles. These reports have indicated that these vehicles, when operated in specific cold climate areas (Cold Climate States1) with high road salt usage, or exposed to other environmental factors, may exhibit more-than-normal corrosion to the vehicle’s frame. 2 PREPARATION A. TOOLS & EQUIPMENT • • • • • • • • • • • • • • • • • • • • A/C service equipment Alignment rack Brake bleeder Engine hanger 2GR-FKS Engine − 12281-31121 – Engine hanger no. 1 (Qty: 1) − 12282-31100 – Engine hanger no. 2 (Qty: 1) − 90119-A0117 – Bolt (Qty: 4) 2TR-FE Engine − 12281-75050 – Engine hanger (Qty: 2) − 91672-81025 – Bolt (Qty: 2) Engine hoist (Qty: 2) or Hydraulic mini crane (Qty 2) Engine sling (Qty: 2) Protective eyewear Protective gloves Ratcheting tie down strap (2 in X 27 ft, minimum work load capacity: 3,000 lbs) Special Service Tools (SST) 09325-40010 – Transmission oil plug (2WD) 09628-62011 – Ball joint puller 09520-32040 – A component of SST 09520-24010, Differential side gear shaft puller 09520-01010 – Drive shaft remover attachment 09628-00011 – Ball joint puller 09922-10010-01 – Variable open wrench 11816-00010 - Radar Sensor Calibration Kit Standard hand tools Techstream Torque wrench Torx® T55H socket Socket wrench 35mm Hexagon wrench 8, 10 Deep socket wrench 10, 12, 14, 17, 19mm Union Nut Wrench 10mm Weights Heat Light B. SUPPLIES • • • • • • • • Toyota Genuine ATF WS or DEXRON® lll (DEXRON® ll) – As needed Hypoid gear oil API GL-5 SAE 75W-90 – 1.5 liter (4WD Only) R1234yf refrigerant – As needed Toyota DOT 3 brake fluid – 3 pints Toyota long life coolant – 2 gallons Paint Marker MP Grease General Adhesive Remover 3 THE PARTS INCLUDED IN 2005-2010MY REPLACEMENT PARTS BUT NOT IN 2016-2017MY • 2005-2010MY replacement parts were considered to determine 2016-2017MY replacement parts. • The parts of low breakage possibility in 2016-2017MY are not listed as the replacement parts. (2005-2010MY replacement parts are not changed.) • When removing the reusable parts, be careful to NOT damage and make them non-reusable. Judge if the following parts are reusable or not on the actual vehicle, and order the part individually as needed. 4 C. PARTS To assist dealers in determining the correct part number(s) to order, a website has been set up to look up part numbers by VIN. Please go to https://tacoma-2011-2017-frames.imagespm.info/ select the appropriate campaign/vehicle, enter the VIN, and the correct part numbers to order will be displayed. The website is for part(s) application reference only and won’t order the parts, confirm campaign completion status, or confirm campaign applicability. • The parts will need to be ordered through the Dealer Daily Parts System. • ETAs for the parts will be available via the normal system. • Frame ETAs will be made available on the Dealer Daily website, in the MAC reference area. Note: When first logging in; enter your dealer code and the default password; XXXXX. Upon logging in the website will ask for you to reset the password and provide an email address. An illustration of the parts replaced and their location(s) have been provided. Please reference the “Illustration Name” and ”Page” columns in the parts tables below. Individual Parts: Part Number 04008-20104 04008-20204 04008-20304 04008-20404 04008-20504 04008-20604 04008-17704 04008-20704 04008-20804 04008-20904 Part Description (GRN305 DCB) (GRN305 LCB) (GRN310) (GRN325 DCB) (GRN325 LCB) (GRN330) (TRN245 5F) (TRN245 6FC) (TRN265 DCB) (TRN265 LCB) Quantity Illustration Name Page 1 1 1 1 1 1 1 1 1 1 Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame 11 11 11 11 11 11 11 11 11 11 5 Individual Parts (Continued): Part Number Part Description Quantity 31461-35030 Insulator, Release Cylinder Heat 1 43425-04040 47313-04250 47315-04200 47323-04200 47324-04160 47325-04220 47325-04230 47326-04190 47326-04200 48068-04060 48069-04060 77285-04100 82711-78010 82715-04200 82715-04200 82715-04230 82715-04250 82715-04260 82715-04350 82715-04730 82715-04740 82715-04750 82715-04770 82715-04820 90105-A0066 90119-A0141 90119-A0148 90119-A0151 Ring, Shaft Snap (For Front Drive Inner Shaft Outer) Tube, Front Brake, No.3 Tube, Front Brake, No.5 Tube, Rear Brake, No.3 Tube, Rear Brake, No.4 Tube, Rear Brake, No.5 Tube, Rear Brake, No.5 Tube, Rear Brake, No.6 Tube, Rear Brake, No.6 Arm Sub-Assy, Front Suspension, Lower No.1 RH Arm Sub-Assy, Front Suspension, Lower No.1 LH Clamp, Fuel Tube, No.1 Clamp (For Rear Differential Lock) Bracket (For 2TR-FE A/F Sensor Wiring) Bracket (For Frame Wire No.2) Bracket (For Frame Wire) Bracket (For Rear Differential Lock) Bracket (For Rear Differential Lock) Bracket (For Frame Wire No.2) Bracket (For 4WD Front Differential Wire) Bracket (For Frame Wire) Bracket (For Frame Wire) Bracket (For Frame Wire No.2) Bracket (For 2TR-FE A/F Sensor Wiring) Bolt (For Rear Differential Lock) Bolt (For Front Differential Wire Bracket) Bolt (For W/ Frame Wire No.2) Bolt (For Heat Insulator of Propeller Shaft) 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 90119-A0165 Bolt (For Insulator, Release Cylinder Heat) 4 90119-A0169 90119-A0169 90119-A0169 90119-A0169 90119-A0192 90119-A0193 90119-A0238 90178-16007 Bolt (For 2TR-FE A/F Sensor Wiring) Bolt (For 2GR-FKS W/O Frame Wire No.2) Bolt (For 2TR-FE Frame Wire) Bolt (For 2GR-FKS W/ Frame Wire No.2) Bolt (For W/ Towing Hitch) Bolt (For Front Hook, No.1 W/ Fuel Tank Protector) Bolt (For Frame Wire) Nut (For Front Axle Arm) 2 2 2 6 4 2 2 2 90178-A0048 Nut (For 2GR-FKS Fuel Pump Control Computer) 2 90178-A0112 90179-08241 90917-06083 90949-T1006 90949-T1006 91674-80830 Nut (For Frame Wire) Nut (For W/ Fuel Tank Protector) Gasket, Exhaust Pipe, No.2 Clamp, Brake Tube, No.11 Clamp, Brake Tube, No.11 Bolt (For W/ Front Suspension Member Bracket) 1 4 1 3 4 8 Illustration Name Release Cylinder Heat Insulator Front Suspension Brake Tubes Brake Tubes Brake Tubes Brake Tubes Brake Tubes Brake Tubes Brake Tubes Brake Tubes Front Suspension Front Suspension Fuel Tubes Wire Harness Brackets 2TR-FE Exhaust System Wire Harness Brackets Wire Harness Brackets Wire Harness Brackets Wire Harness Brackets Wire Harness Brackets Wire Harness Brackets Wire Harness Brackets Wire Harness Brackets Wire Harness Brackets 2TR-FE Exhaust System Wire Harness Brackets Wire Harness Brackets Wire Harness Brackets Propeller Shaft Release Cylinder Heat Insulator 2TR-FE Exhaust System Wire Harness Brackets Wire Harness Brackets Wire Harness Brackets Rear Bumper Under Cover Wire Harness Brackets Front Suspension Fuel Pump Control Computer Wire Harness Brackets Fuel Tank 2GR-FKS Exhaust System Brake Tubes Brake Tubes Under Cover Page 20 12 14,15 14,15 14,15 14,15 14,16 15,17 14,16 15,17 12 12 18 19 21 19 19 19 19 19 19 19 19 19 21 19 19 19 21 20 21 19 19 19 22 11 19 12 22 19 18 21 14,16 15,17 11 6 Parts Kits: Part Number Part Description Quantity 04008-07335 Parts Kit No.1 - Common Replacement Kit F 1 The kit listed above includes the following parts: Part Number 90910-03001 90119-16005 94151-21001 90412-10289 Part Description Bolt (For Front Engine Mount) Bolt (For Front Suspension Toe Adjust Cam) Nut (For Front Engine Mount) WAY (For Front Brake Tube) Qty 4 2 4 2 Illustration Name Engine Mounting Front Suspension Engine Mounting Brake Tubes Page 20 12 20 14-17 Part Number Part Description Quantity 04008-22204 Parts Kit No.2 - Common Replacement Kit G 1 The kit listed above includes the following parts: Part Number 16442-0C420 90080-11555 90412-10276 90468-A0007 90171-A0005 90171-A0005 90080-17215 90177-A0010 90119-A0169 51719-04010 90178-A0044 90119-A0192 90119-A0249 90210-A0002 90301-A0006 Part Description Packing (For Radiator Drain Cock) Bolt (For Steering Intermediate Shaft) Way, 2 (For Rear Brake Tube) Clip (For Brake Tube) Nut, Castle (For Front Lower Ball Joint RH) Nut, Castle (For Front Lower Ball Joint LH) Nut (For Front Suspension Support) Nut (For Rear Shock Absorber) Bolt (For Spare Tire Carrier) Holder, Body Support Bracket Nut (For Front Bumper Extension) Bolt (For Rear Bumper) Bolt (For Fuel Tank Band) O Ring (For Discharge Hose Sub-Assy) O Ring (For Suction Hose Sub-Assy) Qty 1 2 1 4 1 1 6 2 4 2 6 6 2 1 2 Illustration Name Radiator Power Steering Brake Tubes Brake Tubes Front Suspension Front Suspension Front Suspension Rear Suspension Spare Tire Carrier Cab Mounting Front Bumper Rear Bumper Fuel Tank Air Conditioning Air Conditioning Page 22 20 14-17 13-17 12 12 12 13 11 11 22 22 18 22 22 Part Number Part Description Quantity 04006-46104 Parts Kit No.3 – JPN Source Parts Kit 4 1 The kit listed above includes the following parts: Part Number 12157-10010 90430-24003 90311-47027 90311-47026 43514-28010 43514-28010 95381-04045 Part Description Gasket, Front Differential Filler Plug Gasket, Front Differential Drain Plug Seal, Oil (For Differential Side Gear Shaft) Seal, Oil (For Differential Side Gear Shaft) Cap, Front Axle Hub Grease, RH Cap, Front Axle Hub Grease, LH Cotter Pin (For Front Drive Shaft) Qty 1 1 1 1 1 1 2 Illustration Name Front Differential Front Differential Front Differential Front Differential Front Suspension Front Suspension Front Suspension Page 20 20 20 20 12 12 12 7 Part Number Part Description Quantity 04008-07435 Parts Kit No.4 – JPN Source Parts Kit 5 1 Part Number 95381-03225 48190-60040 48190-60040 48198-60020 48198-60020 48409-60040 48452-60020 95381-03230 The kit listed above includes the following parts: Part Description Qty Illustration Name Cotter Pin (For Tie Rod End) 2 Power Steering Cam, Front Suspension Camber Adjust, No.1 RH 1 Front Suspension Cam, Front Suspension Camber Adjust, No.1 LH 1 Front Suspension Cam, Front Suspension Camber Adjust, No.2 RH 1 Front Suspension Cam, Front Suspension Camber Adjust, No.2 LH 1 Front Suspension Cam Sub-Assy, Front Suspension Toe Adjust 2 Front Suspension Plate, Front Suspension Toe Adjust, No.2 2 Front Suspension Cotter Pin (For Front Suspension Lower Arm) 2 Front Suspension Page 20 12 12 12 12 12 12 12 Part Number Part Description Quantity 04008-22404 Parts Kit No.5 – USA Source Parts Kit 6 1 Part Number 17176-31130 90501-A0031 90080-10291 17451-0D060 90080-10064 90080-11180 The kit listed above includes the following parts: Part Description Qty Illustration Name 2GR-FKS Exhaust Gasket, Air Surge Tank to Intake Manifold 1 System 2GR-FKS Exhaust Spring (For Exhaust Pipe) 2 System 2GR-FKS Exhaust Bolt (For Exhaust Pipe) 2 System 2GR-FKS Exhaust Gasket, Exhaust Pipe 1 System 2GR-FKS Exhaust Bolt (For Exhaust Pipe) 2 System 2GR-FKS Exhaust Bolt (For Exhaust Pipe Stopper Bracket) 2 System Page 21 21 21 21 21 21 Part Number Part Description Quantity 04008-22504 Parts Kit No.6 – USA Source Parts Kit 7 1 Part Number 90080-43033 90080-10064 90177-A0004 The kit listed above includes the following parts: Part Description Qty Illustration Name 2TR-FE Exhaust Gasket (Exhaust Pipe) 1 System 2TR-FE Exhaust Bolt (Exhaust Pipe) 2 System 2TR-FE Exhaust Nut (Exhaust Pipe) 2 System Page 21 21 21 8 Part Number 04008-22604 Part Number 77285-04110 90119-A0210 48304-04100 48304-04100 90119-A0192 90080-11373 90080-11373 90189-A0002 75395-35070 75396-35020 53851-04100 53853-04070 53855-04010 75696-04050 75697-04050 75698-04030 Part Number 04008-22804 Part Description Parts Kit No.7 – USA Source Parts Kit 8 The kit listed above includes the following parts: Part Description Qty Illustration Name Clamp, Fuel Tube, No.1 3 Brake Tubes Bolt (For Rear Engine Mount) 4 Engine Mounting Bumper, Front Spring, RH 1 Front Suspension Bumper, Front Spring, LH 1 Front Suspension Bolt (For Hook No.1) 2 Under Cover Bolt (For Engine Under Cover Sub-assy No.1) 4 Under Cover Bolt (For Engine Under Cover Sub-assy No.2) 4 Under Cover Clip (For Left Rear Wheel Well Liner) 6 Moulding Clip, Outside Moulding, No.1 9 Moulding Clip, Outside Moulding, No.2 19 Moulding Pad, Front Wheel Opening Extension 2 Moulding Pad, Front Wheel Opening Extension, No.1 2 Moulding Pad, Front Wheel Opening Extension, No.2 2 Moulding Pad, Body Outside Moulding, No.1 1 Moulding Pad, Body Outside Moulding, No.2 1 Moulding Pad, Body Outside Moulding, No.3 1 Moulding Part Description Parts Kit No.8 – Brake Tube Kit 8 Quantity 1 Page 14-17 20 12 12 11 11 11 22 22 22 22 22 22 22 22 22 Quantity 1 The kit listed above includes the following parts: Part Number 47313-04260 47315-04171 47323-04210 47324-04170 Part Number 04008-23404 Part Description Tube, Front Brake, No.3 Tube, Front Brake, No.5 Tube, Rear Brake, No.3 Tube, Rear Brake, No.4 Qty 1 1 1 1 Illustration Name Brake Tubes Brake Tubes Brake Tubes Brake Tubes Part Description Parts Kit No.9 – Brake Tube Kit 9 Page 16,17 16,17 16,17 16,17 Quantity 1 The kit listed above includes the following parts: Part Number 47314-04160 47316-04160 90119-A0169 Part Number 04008-07635 Part Description Tube, Front Brake, No.4 Tube, Front Brake, No.6 Bolt (For Brake Tube Bracket) Qty 1 1 9 Illustration Name Brake Tubes Brake Tubes Brake Tubes Part Description Plug Hole Kit Frame Replacement 2 Page 14-17 14-17 13-17 Quantity 1 The kit listed above includes the following parts: Part Number 90333-30002 90950-01983 90950-01987 90950-01989 90950-01990 90950-01991 90950-01992 90950-01A24 Part Description PLUG, PLATE PLUG, HOLE PLUG, HOLE PLUG, HOLE PLUG, HOLE PLUG, HOLE PLUG, HOLE PLUG, HOLE Qty 14 4 8 4 2 4 2 2 Illustration Name N/A N/A N/A N/A N/A N/A N/A N/A Page N/A N/A N/A N/A N/A N/A N/A N/A 9 D. PARTS ILLUSTRATION Frame Cab Mounting Under Cover Spare Tire Carrier 10 Front Suspension 11 Rear Suspension Brake Tubes 12 Brake Tubes Continued… 13 Brake Tubes Continued… 14 Brake Tubes Continued… 15 Brake Tubes Continued… 16 Fuel Tank Fuel Tubes 17 Wire Harness Brackets 18 Power Steering Front Differential Engine Mounting Release Cylinder Heat Insulator 19 2GR-FKS Exhaust System 2TR-FE Exhaust System Propeller Shaft 20 Fuel Pump Control Computer Radiator Air Conditioning Front Bumper Rear Bumper Moulding 21 FRAME INSPECTION PERFORM INITIAL PRE-HOIST INSPECTION 1. INSPECT THE FRAME FOR EXCESSIVE FRAME CORROSION THAT COULD AFFECT THE STRUCTURAL INTEGRITY OF THE FRAME FRAME INSPECTION All frame inspection must be performed using the frame inspection application on TIS. Ensure you inspect the frame and properly document the inspection. Failure to perform this will result in denial of the claim. 1. INSPECT FOR FRAME RAIL SEAL a. Inspect if the frame already has a frame rail seal installed as shown in the image below Is the frame rail seal already installed? YES No further action required. Campaign is complete NO Proceed to the next step in the frame inspection 22 2. ACCESS INSPECTION APPLICATION a. Run the VIN in TIS and click on the Warranty Tab. b. Click on the “Frame Inspection” link on TIS. 3. LOG INTO THE INSPECTION APPLICATION a. Reenter your TIS password 23 4. ENTER VEHICLE INFORMATION a. Enter the vehicle mileage. b. Select the state from the drop down menu that the vehicle is registered. Note: Do NOT select the state the dealership is located. c. Select NO CRC Previously Applied: Select Frame Button 5. INSPECT THE FRAME SECTIONS a. Inspect the frame in the colored areas below and use the application to document the results of the inspection. Tacoma 11 to 17 b. Select Section A Note: The frame inspection application must be completed in alphabetical order. 24 Inspect the frame section and inspect all surfaces of the frame rail and crossmember. Select the photo that best represents the frame condition. If perforation of 10mm or larger is identified select “Perforation of the Frame”. Note: You must click the bubble next to the image to select the condition. c. d. If you selected Perforation of the Frame, the application will request more information about the size of perforation(s) and location. e. The section with perforation will split into 2 sub-sections to further identify the perforation location. f. Select the size of the perforation in each sub-section. g. Upload a photo for each area containing perforation and describe the location in the comments section. Note: • Include the R.O in the image of at least one of the perforation holes. • If both sub-sections have perforation, it will require two pictures to be uploaded. • If perforation was accidentally selected, use the back button to reset section. h. Select Next to move onto the next section. 25 Each image attached has a size limit of 3 MB and all images cannot exceed 15 MB total. If 3MB is uploaded the system will display the error shown below. User using Chrome browser may receive intermittent errors when uploading several high-quality images, IE is recommended. i. Once all sections have been completed, select the Submit button. Note: When completed it will be indicated by all sections being grayed out and the submit button will appear. 26 NO Perforation Found j. If no perforation was found, follow the directions as provided. Perforation Found k. If perforation was found, this application will be submitted to your Regional Office for review. The region office will review the inspection and provide feedback if the frame replacement is approved for future repair. DO NOT proceed with frame replacement or parts ordering until you are provided with approval from the Regional Office. Approval will be sent to the inspection technician’s TIS inbox and Service and Parts Manager email. 27 FRAME REPLACEMENT WORK PROCEDURE A. PERFORM PRELIMINARY VEHICLE INSPECTION 1. Perform health check and record any preexisting DTCs 2. Test drive the vehicle and inspect the following vehicle functions/current operating conditions prior to vehicle repair. • • • • • 3. 4WD System (4WD Only) Interior Lights Exterior Lights HVAC System Audio System • • • • Power Windows Power Door Locks All Gauges, Indicators and Warning Lights Etc. Documents the current vehicle operating condition on the Frame Replacement Inspection Sheet. B. SAFETY CHECKLIST & PRECAUTIONS WHEN DRAINING THE FUEL SYSTEM • • • • 1. Always remember “SAFETY FIRST”. Be extremely careful when handling fuel to prevent fires from occurring. Before beginning work on the fuel system, perform the following safety check list. Before removing any fuel system part, drain all fuel to prevent spilling. AIR VENTILATION Perform work in a well-ventilated area. DO NOT work underground or in an area where fuel vapors may fill the room due to poor ventilation. Quickly clean up any spilled fuel with a dry cloth and dissipate the fuel vapors. Dry all cloths that have come in contact with fuel in a well-ventilated area and dispose of them properly (according to applicable local regulations). 2. FIRES AND IGNITION SOURCES ARE STRICTLY PROHIBITED Fires and ignition sources are prohibited while working on the fuel system. Clearly display the sign found on the next page stating “WORKING WITH GASOLINE, NO FIRES OR IGNITION SOURCES”. Smoking is prohibited near the work area. DO NOT work in areas where there are welders, grinders, drills, electric motors, heaters, etc. DO NOT use work lamps or any other electrical appliance due to the risk of sparks flying from the power switch or a rise in temperature. DO NOT use metal hammers while working, due to the risk of flying sparks. DO NOT start any engines or perform any of the above in neighboring work bays. 3. FIRE EXTINGUISHER Have a fire extinguisher ready and available before beginning work. 4. PREVENT STATIC ELECTRICITY To help prevent static electricity, lightly wet the floor with water, but not to the point where it creates a hazardous working condition. Place appropriate warning cones or stand signs around the area as a caution. 5. PRECAUTIONS WHEN USING A LIFT For bays equipped with auto lifts, cover all access cover joints with duct tape. In the event that fuel has leaked inside the auto lift, remove the access cover and clean up any spilled fuel. is gone. 6. Dissipate fuel vapors until the smell PREVENT THE FUEL FROM SPRAYING When disconnecting any fuel tubes, pipes, hoses or connectors there may still be some pressure remaining, even after discharging the system. To prevent the fuel from spraying, cover the tubes, pipes or connectors with a shop rag before disconnecting. Remember to always wear protective goggles especially when disconnecting fuel tubes, pipes, hoses or connectors. 7. PREVENT THE FUEL FROM CONTACTING OTHER PARTS DO NOT allow the fuel to come in contact with any parts made of rubber or leather. 8. ASSIGN A SAFETY SUPERVISOR Assign a safety supervisor to be in charge of all safety precautions and fire hazards around the work area. 28 29 30 C. DISCHARGE THE FUEL SYSTEM PRESSURE • DO NOT disconnect any part of the fuel system until you have discharged the fuel system pressure. • Even after discharging the fuel system pressure, place a piece of cloth around the tubes, pipe, hoses and connectors as you separate them to reduce the risk of fuel spraying on yourself, in the engine compartment and onto other parts. • For additional repair information, please reference the appropriate repair manual in TIS for the vehicle you are working on. 1. CHECK FOR DTCs 2. RECORD THE RADIO STATION PRESETS 2GR-FKS 3. DISCHARGE THE FUEL SYSTEM PRESSURE a) b) c) d) e) f) g) h) i) j) k) l) Remove the No.1 upper relay block cover. Remove the circuit opening relay from the engine room relay block. (2TR-FE Only) Remove the EFI MAIN No.2 relay from the engine room relay block. (2GR-FKS Only) Disconnect the 2 connectors. (2GR-FKS Only) Start the engine. After the engine stops, turn the ignition switch off. NOTE: DTC P0171 (system too lean) may be stored. Check that the engine does not start. Remove the fuel tank cap and let the air out of the fuel tank. Disconnect the negative (-) battery terminal. NOTE: Wait 90 seconds after the negative (-) terminal cable is disconnected from the battery before proceeding. Doing so will prevent the SRS from being deployed (i.e. airbag, seat belt pretensioner, etc.). Connect the 2 connectors. (2GR-FKS Only) Reinstall the EFI MAIN No.2 relay. (2GR-FKS Only) Reinstall the circuit opening relay. (2TR-FE Only) Reinstall the No. 1 upper relay block cover. NOTE: Reinstall the No.1 upper relay block cover to not let foreign objects enter. 31 D. REMOVE THE BED ASSY • If the frame is perforated, ONLY raise the vehicle high enough to remove the tires. • For added safety and support place jack stands under the front and rear portions of the frame. • DO NOT work directly underneath the vehicle when performing bed assy removal. • The actual vehicle specs, equipment and parts required may differ than what is shown. Please use the correct specifications and parts for the model you are working on. • For additional repair information, please reference the appropriate repair manual found on TIS for the vehicle you are working on. 1. CENTER THE VEHICLE BETWEEN THE LIFT ARMS a) Verify the vehicle is aligned with the center point of the lift to prevent interference and damage to the frame and/or lift. 2. REMOVE THE FOLLOWING PARTS • Rear Tail/Combination Light LH/RH • Rear Bumper Assy • Rear Mudguard LH/RH (If Equipped) • Side Step Assy LH/RH (If Equipped) • Quarter Panel Wheel Opening Moulding LH (If Equipped) • Power Outlet Socket Assy (If Equipped) • When removing the parts, be careful not to damage them and surrounding components. • Be cautious when removing the Quarter Panel Wheel Opening Moulding LH to NOT damage or deform, since it will be reused after replacing the clips and double-sided tape attached to the moulding. 3. REMOVE THE FRAME WIRE HARNESS a) Disconnect the clamps, connectors and the frame wire harness from the bed assy. NOTE: • The number of connectors may differ depending on the vehicle specification. • Be careful not to damage the wire harness clamps when removing them. 4. DISCONNECT LEFT REAR WHEEL WELL LINER a) Remove the 8 clips and then disconnect the front side of the left rear wheel well liner. 5. DISCONNECT THE FUEL INLET PIPE SUB-ASSY a) Remove the bolt and disconnect the fuel inlet pipe sub-assy. 32 6. REMOVE THE BED ASSY a) Using a Torx® T55H Socket, remove the 6 Torx ® bolts from the bed assy. NOTE: • Use 4 or more people to remove the bed assy from the frame. • Evenly support the bed assy when removing it. • Be careful not to damage the filler tubes when removing the bed. • Protect the front side of the bed assy to not damage the cab assy. E. REMOVE THE CAB BODY ASSY • If the frame is perforated, ONLY raise the vehicle high enough to remove the tires. • For added safety and support place jack stands under the front and rear portions of the frame. • DO NOT work directly underneath vehicle when performing cab assy removal, unless noted. • The actual vehicle specs, equipment and parts required may differ than what is shown. Please use the correct specs and parts for the model you are working on. • For additional repair information, please reference the appropriate repair manual in TIS for the vehicle you are working on. 1. REMOVE THE FRONT NO.1 WHEEL OPENING EXTENSION PAD (IF EQUIPPED) 2. REMOVE THE ENGINE UNDER COVERS NOTE: Use precaution when performing this step, as you will need to work underneath the vehicle. 3. EVACUATE THE REFRIGERANT FROM THE AIR CONDITIONING SYSTEM 4. REMOVE THE RELEASE CYLINDER HEAT INSULATOR (2GR-FKS MANUAL TRANS ONLY) 5. DRAIN THE FOLLOWING FLUIDS • Coolant • Brake Fluid • Clutch Fluid (2GR-FKS Manual Trans Only) • Front Differential Fluid (4WD Only) NOTE: DO NOT remove the radiator cap while the radiator and engine are hot, doing so may cause the coolant to spray out causing potential injuries. 6. REMOVE THE FOLLOWING BODY COMPONENTS • Radiator Grille • Front Fender Mudguard LH/RH (If Equipped) • Front Fender Wheel Opening Moulding LH/RH • Front Bumper Assy • Front Bumper Reinforcement • Front No.2 Bumper Extension Sub-assy LH/RH (If Equipped) • Be cautious when removing the Front Fender Wheel Opening Moulding LH/RH to NOT damage or deform, since they will be reused after replacing the clips and double-sided tape attached to the moulding. 7. REMOVE THE FOLLOWING INTERIOR COMPONENTS • • • • Front Door Scuff Plate LH/RH Cowl Side Trim Board LH/RH Front Floor Footrest Instrument Side Panel RH • Glove Compartment Plate • Lower No.2 Instrument Panel Airbag Assy • Instrument Lower Panel Assy 33 8. DISCONNECT THE ENGINE WIRE HARNESS a) Disconnect each connector and clamp from the ECM and remove the engine wire harness. NOTE: The number of connectors may differ depending on the model. 9. DISCONNECT THE NO.2 FRAME WIRE HARNESS (IF EQUIPPED) a) Remove the 2 bolts and cover. b) Disconnect the 2 connectors and clamp. 10. REMOVE THE FOLLOWING PARTS • Rear Console Box • Manual Transmission Shift Lever Assy • Voltage Inverter Assy (If Equipped) ( Manual Trans Only) 11. DISCONNECT THE PARKING BRAKE CABLES a) Remove the parking cable end stopper. b) c) Loosen the adjusting nut. Disconnect the 2 parking cables from the parking brake pull rod. Push the 2 parking brake cables out of the vehicle. d) 12. REMOVE THE FOLLOWING PARTS • V-Bank Cover (2GR-FKS Only) • Air Cleaner Hose and Air Cleaner Assy 34 13. DISCONNECT THE NO.2 ENGINE WIRE HARNESS a) Remove the nut and disconnect the (+) positive battery cable. b) Remove the bolt and disconnect the ground wire. c) Disconnect the 2 clamps. NOTE: The number of clamps may differ depending on the model. d) Disconnect the connector. e) f) Remove the No.1 upper relay block cover. Disconnect the 5 connectors. NOTE: The number of connectors may differ depending on the model. g) Disconnect the 2 clamps. h) Remove the nut and disconnect the fuse box wire harness. i) Reinstall the No.1 upper relay block cover. LH Side 14. DISCONNECT THE SKID CONTROL SENSOR WIRE HARNESS a) Disconnect the harness clamp and front skid control sensor connector. Repeat the procedure on the opposite side. b) RH Side 15. DISCONNECT THE NO.2 FRAME WIRE HARNESS (IF EQUIPPED) a) Disconnect the harness clamp and connector. 16. DISCONNECT THE FRONT DIFFERENTIAL BREATHER TUBES (4WD ONLY) a) Disconnect the front differential breather tubes. 35 17. DISCONNECT THE FUEL PIPES AND VAPOR FEED HOSE a) b) c) Remove the fuel pipe clamps. Disconnect the 2 fuel pipes. Remove the clip and disconnect the fuel vapor feed hose. NOTE: Put a shop towel under the fuel pipe to catch any spilled fuel. 2TR-FE 18. DISCONNECT THE VACUUM HOSE a) Disconnect the vacuum hose. 2GR-FKS 19. DISCONNECT THE RADIATOR HOSES a) Disconnect the inlet and outlet radiator hoses from engine. Be careful not to damage the radiator hoses. 20. REMOVE THE FOLLOWING PARTS • Radiator Support to Frame Seal • Fan Shroud • Radiator Assy ･Do not remove the radiator side deflectors. ･Be careful not to over-flex the deflectors when removing the radiator assy. 21. DISCONNECT THE NO.1 HOSE (2TR-FE ONLY) a) Disconnect the No.1 hose from the air pump assy. 22. DISCONNECT THE POWER STEERING PUMP OIL RESERVOIR ASSY (2GR-FKS ONLY) a) Disconnect power steering pump oil reservoir assy. 36 23. DISCONNECT THE ENGINE WIRE HARNESS a) b) Disconnect the clamp. Remove the engine wire harness container from the cowl panel. 24. DISCONNECT THE WATER / HEATER HOSES, ENGINE SIDE (2GR-FKS ONLY) 25. DISCONNECT THE WATER / HEATER HOSES, HEATER RADIATOR SIDE (2TR-FE ONLY) LH Side 26. REMOVE THE FRONT FENDER APRON SEALS a) Remove the 20 clips and 4 front fender apron seals. RH Side 27. DISCONNECT THE AIR CONDITIONING DISCHARGE HOSE FROM THE COMPRESSOR 2GR-FKS 28. DISCONNECT THE SUCTION HOSE FROM THE AIR CONDITIONING UNIT ASSY 2TR-FE 37 LH Side 29. DISCONNECT THE FRONT BRAKE TUBES a) b) Disconnect the front brake tube. Repeat the procedure on the opposite side. RH Side 30. DISCONNECT THE STEERING SLIDING YOKE NOTE: Use precaution when performing this step, as you will need to work underneath the vehicle. a) b) c) d) e) Make sure the front wheels are in a straight-ahead position and the steering wheel is centered. Using the seat belt, hold the steering wheel in position as shown in the illustration, to prevent damage to the spiral cable. Place matchmarks on the steering sliding yoke and No.2 intermediate shaft. Loosen bolt (A) and remove bolt (B). Disconnect the steering sliding yoke from the No.2 intermediate shaft. NOTE: If the steering sliding yoke is stuck, tap it from below with a brass hammer to disconnect it. 31. DISCONNECT THE SHIFT CABLE (AUTO TRANS ONLY) a) b) Remove the clip. Remove the nut and disconnect the shift cable. NOTE: Use precaution when performing this step, as you will need to work underneath the vehicle. 32. DISCONNECT THE CLUTCH RELEASE CYLINDER ASSY (2TR–FE MANUAL TRANS ONLY) a) b) Remove the bolt and disconnect the clutch hose. Remove the 2 bolts and disconnect the clutch release cylinder. NOTE: Use precaution when performing this step, as you will need to work underneath the vehicle. 38 33. DISCONNECT THE NO.1 CLUTCH HOSE (2GR-FKS MANUAL TRANS ONLY) a) b) Disconnect the clutch release cylinder tube from the clutch hose. Remove the clip and disconnect the clutch hose. 34. DISCONNECT THE NO.2 FUEL HOSE a) Remove the clip and disconnect the No.2 fuel hose. NOTE: Use precaution when performing this step, as you will need to work underneath the vehicle. 35. DISCONNECT THE FUEL TANK TUBES a) b) Remove the fuel pipe clamp. Disconnect the 2 fuel tank tubes. NOTE: Use precaution when performing this step, as you will need to work underneath the vehicle. 36. DISCONNECT THE REAR BRAKE TUBES a) Disconnect the 2 rear brake tubes. NOTE: Use precaution when performing this step, as you will need to work underneath the vehicle. 39 37. REMOVE THE FOLLOWING PARTS (ACCESS CAB ONLY) • Floor Board No.1/No.2 • Seat Floor Box • Rear Floor Side Service Hole Cover LH/RH • Rear Lower Console Box • Rear Seat Cushion Assy 38. REMOVE THE CAB BODY ASSY USING AN ABOVE GROUND LIFT a) Remove the 4 hole plugs. b) Remove the 6 nuts, 6 washers and 6 bolts. c) Set the lift arms under the cab body assy so they DO NOT interfere with the frame or cab mounts. d) Check that all wire harnesses, hoses, cables and the steering shaft are disconnected. e) Mark the location of the tires so it will be easier to install the cab onto the new frame. f) Lift the cab assy up slowly, making sure it does not interfere with anything while being raised. g) Raise the cab assy high enough so that the top of the engine clears the lowest point of the cab assy. h) Pull the frame assy out from under the vehicle. i) Lower the cab assy all the way down and leave it on the lift. j) Reinstall the 6 bolts, they will be used as guides during cab assy reinstallation. NOTE: • Center the cab assy weight on the lift arms so that it does not slant/tilt to one side. • Raise the cab assy slightly off the frame and verify that it is held securely by the lift arms. • The center of gravity of the cab body may become nose heavy depending on placement of the lift arm which could cause the cab to fall when lifted. To prevent this, use weights to establish a balance and secure the cab body to the lift arm using ratchet tie down belts. • DO NOT work directly underneath the vehicle when pulling the frame assy out from under. 40 F. DISASSEMBLE THE FRAME 1. PLACE THE FRAME ON A LIFT a) Place the frame on the lift, and secure it with a ratcheting tie down strap. tilting or falling off as parts are removed. This will prevent the frame from • Ratcheting Tie Downs: Qty 1 (Length: 2 in X 27 ft and Min. Work Load Capacity: 3,000 lbs) 2. DISCONNECT THE FRONT PROPELLER SHAFT ASSY (4WD ONLY) a) 3. Remove the 4 nuts from transfer case side of the front propeller shaft assy. REMOVE THE FOLLOWING PARTS • Wheels • Propeller Shaft Heat Insulator (If Equipped) • Rear Propeller Shaft Assy • Exhaust Pipe Stopper Bracket (If Equipped) • Brake Tube Heat Insulator (If Equipped) • Insert SST 09325-40010 into trans after the Rear Prop Shaft is removed to prevent oil leakage (2WD Only) NOTE: Place matchmarks on the front (if equipped) and rear propeller shafts prior to removal. 4. 5. REMOVE THE EXHAUST SYSTEM (2GR-FKS ONLY) a) b) Remove the 4 bolts and 2 springs. Disconnect the 5 exhaust pipe supports from the frame and remove the center exhaust pipe assy. c) d) Remove the 2 exhaust pipe gaskets. Disconnect the exhaust pipe support from the frame. REMOVE THE EXHAUST SYSTEM (2TR-FE ONLY) a) b) c) d) e) Remove the 2 bolts and 2 nuts. Disconnect the 4 exhaust pipe supports from the frame and remove the center exhaust pipe assy. Remove the exhaust pipe gasket. Disconnect the 2 oxygen sensor wire harness clamps. Disconnect the exhaust pipe support from the frame. 41 6. REMOVE THE FOLLOWING PARTS • No.1 Fuel Tank Protector Assy (If Equipped) • Fuel Tank • No.2 Fuel Tank Protector (If Equipped) • Charcoal Canister Assy • Fuel Tank Strap • V-belt 7. REMOVE AND SET ASIDE THE POWER STEERING PUMP ASSY a) Disconnect the connector. b) Remove the bolt and disconnect the ground wire. (2GR-FKS Only) c) Remove the 2 bolts and the power steering vane pump. NOTE: • DO NOT disconnect the power steering pump hoses or tubes. • Keep the power steering pump reservoir upright to prevent the fluid from leaking out. 8. REMOVE THE FOLLOWING PARTS • Intake Air Surge Tank (2GR-FKS Only) • Intake Air Connector (2TR-FE Only) 9. LH Side DISCONNECT THE OIL COOLER TUBE (AUTO TRANS ONLY) a) Remove the bolts and disconnect the oil cooler tube. 10. REMOVE THE ENGINE AND TRANSMISSION ASSY a) Remove the bolt and disconnect the ground wire. (LH Side) b) Disconnect the connector and clamp. (4WD Only) c) Disconnect the clamp. (2TR-FE Only) d) Disconnect and remove the necessary items/parts to prepare the engine and transmission assy for removal. e) Install the engine hanger. 4WD Only For 2GR-FKS: 12281-31121 = No.1 Engine Hanger 12282-31100 = No.2 Engine Hanger 90119-A0117 = 4 Bolts 2TR-FE Only For 2TR-FE: 12281-75050 = 2 Engine Hangers 91672-81025 = 2 Bolts 42 f) Remove the engine and transmission assy. NOTE: • Hang up the front exhaust pipe with string to avoid applying pressure at the joint part. (2TR-FE Only) • ALWAYS use 2 engine hoists/cranes to lift it. • DO NOT use 1 engine hoist/crane to lift the engine & transmission assy, as the unbalanced weight may lead to an accident or injury. • ONLY use engine hoists/cranes that can properly support the weight of the engine and transmission assy. • Carefully adjust the 2 engine hoists/cranes used so that the engine and transmission assy is properly balanced. Be careful not to damage exhaust system while removing the engine and transmission assy. 11. REMOVE THE FRONT PROPELLER SHAFT (4WD ONLY) 12. DISCONNECT THE FRONT SKID CONTROL SENSOR WIRE HARNESS a) b) Remove the bolt and disconnect the skid control sensor wire harness. Repeat the procedure on the opposite side. 13. DISCONNECT THE FRONT BRAKE HOSE a) b) c) Disconnect the front brake tube from the brake hose. Remove the bolt and disconnect the front brake hose and flexible hose bracket. Repeat the procedure on the opposite side. 14. REMOVE THE FOLLOWING PARTS • Front Axle Hub Grease Cap (4WD Only) • Front Axle Shaft Nut (4WD Only) • Tie Rod End* • Front Stabilizer Link Assy • Lower Ball Joint Attachment** * SST 09628-62011 disconnect the tie rod end. **SST 09628-00011 43 15. REMOVE THE FRONT SUSPENSION UPPER ARM AND STEERING KNUCKLE ASSY a) b) Remove the bolt, nut, 2 washers and front suspension upper arm w/ steering knuckle. Repeat the procedure on the opposite side. NOTE: If the drive shaft is difficult to disconnect, tap the drive shaft loose with a plastic hammer. 16. REMOVE THE FOLLOWING PARTS • • • • Front Drive Shaft Assy (4WD Only) * • Front Shock Absorber Assy Front Suspension Member Brace Sub-Assy • Power Steering Link Assy w/ Pump Front Suspension Member Bracket • Front Differential Carrier (4WD Only) Front Stabilizer Bar *SST 09520-24010 (09520-32040), 09520-01010 NOTE: • When removing the power steering link with the pump, have one person support the power steering link and the other support the pump and keep it upright to avoid fluid leakage. • If the drive shaft is difficult to remove tap it with a plastic hammer. • Be careful not to damage the dust cover and oil seal. 17. DISCONNECT THE PARKING BRAKE CABLES a) Remove the 6 bolts and disconnect the parking brake cables. 18. REMOVE THE FUEL PUMP CONTROL ECU (2GR-FKS ONLY) a) b) Disconnect the 2 connectors. Remove the 2 nuts and fuel pump control ECU. 19. REMOVE THE FRAME WIRE HARNESS a) b) c) Remove the 2 bolts and disconnect the ground wire. Remove the 2 bolts and disconnect the frame wire harness. Disconnect the clamps and remove the frame wire harness. NOTE: • The number of wire harness clamps will differ depending on the vehicle specification. • Take care not to damage or break the wire harness clamps during removal. 44 20. REMOVE THE NO.2 FRAME WIRE HARNESS (IF EQUIPPED) a) Disconnect the clamps and remove the frame wire harness. NOTE: • The number of wire harness clamps will differ depending on the vehicle specification. • Take care not to damage or break the wire harness clamps during removal. 21. REMOVE THE NO.2 FLEXIBLE HOSE BRACKET a) b) c) d) Disconnect the No.5 rear brake tube. Disconnect the No.6 rear brake tube. Remove the 2 clips and disconnect the 2 brake hoses. Remove the 2 bolts and No.2 flexible hose bracket. 22. REMOVE THE SPARE TIRE CARRIER ASSY 23. DISCONNECT THE LEAF SPRING AND SHOCK ABSORBER ASSY 24. REMOVE THE SKID CONTROL SENSOR WIRE BRACKET (W/ REAR DIFFERENTIAL LOCK ONLY) a) b) c) d) Remove the bolt. Cut the clamp (A) using nippers. Disconnect the 2 clamps and 2 connectors to remove the 2 brackets. Remove the clamp (A) from the bracket. 25. REMOVE THE NO.2 CHARCOAL CANISTER PIPE a) Disconnect the clamps and remove the No.2 charcoal canister pipe. 45 26. REMOVE THE FRAME AUXILIARY CROSSMEMBER EXTENSIONS (IF EQUIPPED) a) Remove the 2 bolts and frame auxiliary crossmember extensions. 27. REMOVE THE HOOK a) Remove the 2 bolts and hook. 28. REMOVE THE REAR ENGINE MOUNTING REINFORCES (2GR-FKS ONLY) a) Remove the 2 bolts and 2 rear engine mounting reinforces. 29. REMOVE THE NO.1 RECEIVER HITCH ATTACHMENT REINFORCEMENT (IF EQUIPPED) a) Remove the 2 bolts and No.1 receiver hitch attachment reinforcement. 30. REMOVE THE CAB MOUNTS 31. REMOVE THE FRAME FROM THE LIFT a) Remove the ratcheting tie down strap and the frame from the lift. G. PLUG HOLES IN REPLACEMENT FRAME 1. PLACE THE NEW FRAME ON THE LIFT a) Place the NEW frame on the lift, and secure it with a ratcheting tie down strap. • Ratcheting Tie Downs: Qty 1 (Length: 2 in X 27 ft and Min. Work Load Capacity: 3,000 lbs) b) Install all plugs. Use the picture found in appendix to reference the plug installation. NOTE: • You may have to remove certain stickers to install optional equipment. • You may NOT install all the plugs in plug kit. • Make sure all the plugs are flush with the frame. • Make sure the surface of the frame is clean before you apply stickers. 46 H. ASSEMBLE THE FRAME NEW Replacement Parts Part # Part Name 51719-04010 Holder, Body Support Bracket Kit # 2 Qty 2 1. INSTALL THE NEW CLIPS 2. INSTALL THE NO.1 RECEIVER HITCH ATTACHMENT REINFORCEMENT (IF EQUIPPED) a) Install the No.1 receiver hitch attachment reinforcement with the 2 bolts and torque to spec. Torque Spec: 45 N∙m (459 kgf∙cm, 33 ft∙lbf) b) Part # 90119-A0151 NEW Replacement Parts Part Name Bolt *Individual Part(s) 3. Kit # NA* Qty 2 Repeat the procedure on the opposite side. REINSTALL THE PROPELLER SHAFT HEAT INSULATOR (IF EQUIPPED) a) Reinstall the propeller shaft heat insulator with the 2 NEW bolts and torque to spec. Torque Spec: 15.7 N∙m (160 kgf∙cm, 12 ft∙lbf) Part # 82715-04820 82715-04200 90119-A0169 NEW Replacement Parts Part Name Bracket Bracket Bolt *Individual Part(s) Kit # NA* NA* NA* Qty 1 1 2 4. INSTALL THE NEW OXYGEN SENSOR BRACKETS (2TR-FE ONLY) a) Install the 2 NEW brackets with the 2 NEW bolts and torque to spec. Torque Spec: 29 N∙m (296 kgf∙cm, 21 ft∙lbf) 5. REINSTALL THE REAR ENGINE MOUNTING REINFORCES (2GR-FKS ONLY) a) Reinstall the rear engine mounting reinforces with the 2 bolts and torque to spec. Torque Spec: 31 N∙m (316 kgf∙cm, 23 ft∙lbf) 47 Part # 90119-A0192 90119-A0193 NEW Replacement Parts Part Name Bolt Bolt *Individual Part(s) Kit # 7 NA* Qty 2 2 6. REINSTALL THE HOOK a) Reinstall the hook with the 2 NEW bolts and torque to spec. Torque Spec: 70 N∙m (714 kgf∙cm, 52 ft∙lbf) 7. REINSTALL THE FRAME AUXILIARY CROSSMEMBER EXTENSION (IF EQUIPPED) a) Reinstall the 2 frame auxiliary crossmember extensions with the 2 bolts and torque to spec. Torque Spec: 45 N∙m (459 kgf∙cm, 33 ft∙lbf) 8. REINSTALL THE CAB MOUNTS a) b) Reinstall cab mounts No.1 Reinstall cab mounts No.2 and No.3 with the 8 bolts and torque to spec. Torque Spec: 61 N∙m (622 kgf∙cm, 45 ft∙lbf) 9. INSTALL THE NEW FRONT SUSPENSION LOWER ARM a) Install the NEW front suspension lower arm with the NEW bolt, NEW nut, NEW toe adjust cam, NEW No.2 toe adjust cam, NEW No.1 camber adjust cam and NEW No.2 camber adjust cam, then torque to spec. Torque Spec: Bolt - 183 N∙m (1866 kgf∙cm, 135 ft∙lbf) Nut - 188 N∙m (1917 kgf∙cm, 137 ft∙lbf) b) Repeat the procedure on the opposite side. Part # 48068-04060 48069-04060 48190-60040 48198-60020 48409-60040 48452-60020 90119-16005 90178-16007 NEW Replacement Parts Part Name Arm Sub-Assy, Front Suspension, Lower No.1 RH Arm Sub-Assy, Front Suspension, Lower No.1 LH Cam, Front Suspension Camber Adjust, No.1 LH/RH Cam, Front Suspension Camber Adjust, No.2 LH/RH Cam Sub-Assy, Front Suspension Toe Adjust Plate, Front Suspension Toe Adjust, No.2 Bolt Nut *Individual Part(s) Kit # Qty NA* 1 NA* 1 4 2 4 2 4 2 4 2 1 NA* 2 2 48 Part # 48304-04100 NEW Replacement Parts Part Name Bumper, Front Spring, LH/RH 10. INSTALL THE NEW FRONT SPRING BUMPER Kit # 7 Qty 2 a) Using the SST 09922-10010-01, install the NEW front spring bumpers and torque to spec. Torque Spec: 31 N∙m (316 kgf∙cm, 23 ft∙lbf) b) Repeat the procedure on the opposite side. 11. INSTALL THE NEW REAR BRAKE TUBES a) Install the NEW rear brake tubes with the NEW clamp(s). Part # 47325-04220 47325-04230 47326-04190 47326-04200 77285-04110 90949-T1006 90949-T1006 NEW Replacement Parts Part Name Kit # Qty Tube, Rear Brake, No.5** NA* 1 Tube, Rear Brake, No.6** NA* 1 Clamp, Fuel Tube, No.1 7 Clamp, Brake Tube, No.11 NA* 3 3 4 *Individual Part(s) ** Only 1 part used, part number varies by vehicle type. 12. REINSTALL THE NO. 2 CHARCOAL CANISTER PIPE a) b) Part # 90119-A0169 Part # 82711-78010 82715-04250 82715-04260 90105-A0066 NEW Replacement Parts Part Name Bolt NEW Replacement Parts Part Name Clamp Bracket Bracket Bolt *Individual Part(s) Install the fuel return and main tube support. Reinstall the No.2 charcoal canister pipe. 13. REINSTALL THE SPARE TIRE CARRIER ASSY Kit # 2 Qty 4 Kit # NA* NA* NA* NA* Qty 1 1 1 1 a) Reinstall the spare tire carrier assy with the 4 NEW bolts and torque to spec. Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf) 14. INSTALL THE NEW SKID CONTROL SENSOR WIRE BRACKET (W/ REAR DIFFERENTIAL LOCK ONLY) a) Install the NEW clamp (A). b) Install the 2 NEW brackets with the 2 clamps and 2 connectors. c) Install the NEW bolt. Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf) 49 Part # 90177-A0010 NEW Replacement Parts Part Name Nut Kit # 2 Qty 2 15. REINSTALL THE LEAF SPRINGS AND SHOCK ABSORBER ASSY a) Reinstall the leaf springs with the 4 bolts, 4 washers and 4 nuts, then torque to spec. Torque Spec: 120 N∙m (1224 kgf∙cm, 89 ft∙lbf) b) Reinstall the shock absorber assy with the 2 NEW nuts, 2 retainers and 2 cushions, then torque to spec. Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf) Part # 90119-A0169 90468-A0007 NEW Replacement Parts Part Name Bolt Clip Kit # 9 2 Qty 2 2 16. REINSTALL THE NO.2 FLEXIBLE HOSE BRACKET a) b) c) Reinstall the No.2 flexible hose bracket with the 2 NEW bolts. Reconnect the 2 brake hoses with the 2 NEW clips. Reconnect the No.5 and No.6 rear brake tubes, then torque to spec. Torque Spec: Flexible hose bracket - 29 N∙m (296 kgf∙cm, 21 ft∙lbf) Rear brake tube - 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf) Part # 82715-04200 82715-04350 82715-04770 90119-A0169 NEW Replacement Parts Part Name Bracket Bracket Bracket Bolt *Individual Part(s) Front Side Kit # NA* NA* NA* NA* Qty 1 1 1 4 17. INSTALL THE NEW NO.2 FRAME WIRE HARNESS BRACKETS (IF EQUIPPED) a) Install the 3 NEW brackets with the 4 NEW bolts and torque to spec. Torque Spec: 29 N∙m (296 kgf∙cm, 21 ft∙lbf) Rear Side 18. REINSTALL THE NO.2 FRAME WIRE HARNESS (IF EQUIPPED) a) Reconnect the clamps to install the No.2 frame wire harness. NOTE: The number of wire harness clamp will differ depending on the vehicle spec. 50 NEW Replacement Parts Part Name Kit # Bracket NA* Bracket NA* Bracket NA* Bolt NA* Nut NA* *Individual Part(s) Front Side Rear Side Part # 82715-04230 82715-04740 82715-04750 90119-A0169 90178-A0112 Qty 1 1 1 2 1 Part # 90119-A0238 NEW Replacement Parts Part Name Bolt *Individual Part(s) Kit # NA* Qty 2 Part # 90178-A0048 NEW Replacement Parts Part Name Nut *Individual Part(s) Kit # NA* Qty 2 19. INSTALL THE NEW FRAME WIRE HARNESS BRACKETS a) Install the 3 NEW brackets with the 2 NEW bolts and NEW nut, then torque to spec. Torque Spec: Bolt - 14 N∙m (143 kgf∙cm, 10 ft∙lbf) Nut - 20 N∙m (204 kgf∙cm, 15 ft∙lbf) 20. REINSTALL THE FRAME WIRE HARNESS a) b) Reconnect the clamps to install the frame wire harness. Reconnect the frame wire harness with the 2 NEW bolts and torque to spec. Torque Spec: 19.5 N∙m (199 kgf∙cm, 14 ft∙lbf) c) Reconnect the ground wire with the 2 bolts and torque to spec. Torque Spec:19 N∙m (194 kgf∙cm, 14 ft∙lbf) NOTE: The number of wire harness clamps will differ depending on the vehicle spec. 21. REINSTALL THE FUEL PUMP CONTROL ECU (2GR-FKS ONLY) a) Reinstall the fuel pump control ECU with the 2 NEW nuts and torque to spec. Torque Spec: 19 N∙m (194 kgf∙cm, 14 ft∙lbf) b) Reconnect the connector. 22. RECONNECT THE PARKING BRAKE CABLES a) Reinstall the 2 parking brake cables with the 6 bolts, then torque to spec. Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf) 51 Part # 82715-04730 90119-A0141 NEW Replacement Parts Part Name Bracket Bolt *Individual Part(s) 2TR-FE Kit # NA* NA* Qty 1 1 23. REINSTALL THE FRONT DIFFERENTIAL CARRIER (4WD ONLY) a) Apply adhesive to the serration bolt. b) Reinstall the front differential carrier with the 2 bolts, 4 stoppers and 3 nuts, then torque to spec. Torque Spec: Except TMMTX Made Bolt - 137.3 N∙m (1400 kgf∙cm, 101 ft∙lbf) Nut - 87.2 N∙m (889 kgf∙cm, 64 ft∙lbf) Torque Spec: TMMTX Made Bolt - 128.5 N∙m (1310 kgf∙cm, 95 ft∙lbf) Nut - 81.5 N∙m (831 kgf∙cm, 60 ft∙lbf) c) Disconnect the connector from the bracket. d) Remove the bolt and bracket. e) Install the NEW bracket with the NEW bolt and torque to spec. Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf) 24. REINSTALL THE POWER STEERING LINK ASSY W/ POWER STEERING VANE PUMP a) Reinstall the power steering link assy w/ power steering vane pump with the bolts and nuts, then torque to spec. Bolt A - 95 N∙m (969 kgf∙cm, 70 ft∙lbf) Bolt B - 28 N∙m (286 kgf∙cm, 21 ft∙lbf) NOTE: • When reinstalling the power steering link with the pump, have one person support the power steering link and the other support the pump. • Keep the power steering pump reservoir upright to prevent the fluid from leaking out. 2GR-FKS Towing Package Only 25. RECONNECT THE FRONT DIFFERENTIAL BREATHER TUBE (4WD ONLY) a) Reconnect the front differential breather tube with the bolt and 2 clamps, then torque to spec. Torque Spec: 12.7 N∙m (130 kgf∙cm, 9 ft∙lbf) 52 Part # 90080-17215 NEW Replacement Parts Part Name Nut 26. REINSTALL THE FRONT SHOCK ABSORBER ASSY Kit # 2 Qty 6 a) b) Install the 3 NEW nuts (A) and torque to spec. Reinstall the front shock absorber assy with the bolt and nut (B), then torque to spec. Torque Spec: Nut A - 64 N∙m (653 kgf∙cm, 47 ft∙lbf) Nut B - 83 N∙m (846 kgf∙cm, 61 ft∙lbf) c) Repeat the procedure on the opposite side. 27. REINSTALL THE FRONT STABILIZER BAR a) Reinstall the stabilizer bar with 2 brackets and 4 bolts, then torque to spec. Torque Spec: 50 N∙m (510 kgf∙cm, 37 ft∙lbf) Part # 91674-80830 NEW Replacement Parts Part Name Bolt *Individual Part(s) Kit # NA* Qty 8 28. REINSTALL THE FRONT SUSPENSION MEMBER BRACKET a) Reinstall the front suspension member bracket with NEW 8 bolts and torque to spec. Torque Spec: 33 N∙m (337 kgf∙cm, 24 ft∙lbf) 29. REINSTALL THE FRONT SUSPENSION MEMBER BRACE SUB-ASSY a) Reinstall the front suspension member brace sub-assy with 7 bolts and torque to spec. Torque Spec: 45 N∙m (459 kgf∙cm, 33 ft∙lbf) 30. REINSTALL THE FRONT DRIVE SHAFT ASSY (4WD ONLY) NEW Replacement Parts Part Name Ring, Shaft Snap (For Front 43425-04040 Drive Inner Shaft Outer) 90311-47026 Seal, Oil (For Differential Side Gear Shaft) 90311-47027 *Individual Part(s) Part # Kit # Qty NA* 2 3 1 a) b) c) d) e) Remove the oil seal. Install the NEW oil seal. Install a NEW snap ring. Reinstall the front drive shaft assy. Repeat the procedure on the opposite side. NOTE: Be careful not to damage the dust cover and oil seal. 31. REINSTALL THE FRONT SUSPENSION UPPER ARM AND STEERING KNUCKLE ASSY a) Reinstall the front suspension upper arm w/ steering knuckle with the bolt, nut and 2 washers, then torque to spec. Torque Spec: Nut - 115 N∙m (1173 kgf∙cm, 85 ft∙lbf) b) Repeat the procedure on the opposite side. 53 32. REINSTALL THE FOLLOWING PARTS NEW Replacement Parts Part # 95381-03225 Tie Rod End Part Name Cotter Pin Lower Ball Joint Attachment Part Name Nut, Castle (For Front Lower 90171-A0005 Ball Joint) 95381-03230 Cotter Pin Part # Part # 47314-04160 47316-04160 90119-A0169 90412-10289 NEW Replacement Parts Part Name Tube, Front Brake, No.4 Tube, Front Brake, No.6 Bolt Way (For Front Brake Tube) Part # 90119-A0169 90468-A0007 NEW Replacement Parts Part Name Bolt Clip Kit # 4 Qty 2 Kit # Qty 2 2 4 2 Kit # 9 9 9 1 Kit # 9 2 Qty 1 1 2 2 Qty 2 2 • Lower Ball Joint Attachment Reinstall the lower ball joint attachment with the NEW nut and 2 bolts, then torque to spec. Torque Spec: Nut - 140 N∙m (1428 kgf∙cm, 103 ft∙lbf) Bolt - 160 N∙m (1632 kgf∙cm, 118 ft∙lbf) Install the NEW cotter pin. Repeat the procedure on the opposite side. • Front Stabilizer Link Assy Reinstall front stabilizer link with 2 nuts, then torque to spec. Torque Spec: 70 N∙m (714 kgf∙cm, 52 ft∙lbf) Repeat the procedure on the opposite side. • Tie Rod End Reinstall tie rod end with nut and torque to spec. Torque Spec: 91 N∙m (928 kgf∙cm, 67 ft∙lbf) Install the NEW cotter pin. Repeat the procedure on the opposite side. • Front Axle Shaft Nut (4WD Only) Temporarily reinstall the front axle nut. Nut will be tightened when the vehicle is completed. Repeat the procedure on the opposite side. 33. INSTALL THE NEW FRONT BRAKE TUBE AND NEW 2 WAY a) Temporarily install the NEW front brake tube and NEW 2 way. b) Install the NEW bolt to the 2 way and torque to spec. Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf) c) Repeat the procedure on the opposite side. 34. REINSTALL THE FRONT BRAKE HOSE a) Reinstall the flexible hose bracket with the NEW bolt and torque to spec. Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf) b) Reconnect the front brake hose with a NEW clip. c) Reconnect the front brake tube and torque to spec. Torque Spec: 15. 2 N∙m (155 kgf∙cm, 11 ft∙lbf) d) Repeat the procedure on the opposite side. 35. RECONNECT THE FRONT SKID CONTROL SENSOR WIRE HARNESS a) Reinstall the front skid control sensor wire harness with bolt and torque to spec. Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf) b) Repeat the procedure on the opposite side. 54 36. REINSTALL THE WHEELS 37. REINSTALL THE FRONT PROPELLER SHAFT ASSY (4WD ONLY) a) Referencing the matchmarks, reinstall the propeller shaft assy to the front differential. b) Reinstall the 4 bolts, 4 washers and 4 nuts, then torque to spec. Torque Spec: 88.2 N∙m (899 kgf∙cm, 65 ft∙lbf) 38. REINSTALL THE ENGINE AND TRANSMISSION ASSY a) Reinstall engine and transmission assy. NOTE: • Hang up the front exhaust pipe with string to avoid applying pressure at the joint part. (2TR-FE Only) • Use 2 engine hoists/cranes to lift engine & trans assy. • DO NOT use 1 engine hoist/crane to lift the engine & trans assy, the unbalanced weight may lead to an accident or injury. • ONLY use engine hoists/cranes that can properly support the weight of the engine & trans. • Carefully adjust the 2 engine hoists/cranes used so that the engine & trans assy is balanced. Part # 90910-03001 94151-21001 NEW Replacement Parts Part Name Bolt Nut LH Side b) Kit # 1 1 Qty 4 4 Kit # 7 Qty 4 Attach the engine mounts with the 4 NEW bolts and 4 NEW nuts, then torque to spec. Torque Spec: 50 N∙m (510 kgf∙cm, 37 ft∙lbf) RH Side Part # 90119-A0210 NEW Replacement Parts Part Name Bolt c) Attach the transmission mount with 4 NEW bolts and torque to spec. Torque Spec: 21 N∙m (214 kgf∙cm, 15 ft∙lbf) d) e) Remove the bolt(s) and the engine hangers. Reinstall the items/parts that were removed during the engine and transmission assy removal. 55 LH Side f) Reinstall the bolt and reconnect the ground wire. (LH Side) Torque Spec: 19 N∙m (194 kgf∙cm, 14 ft∙lbf) g) Reconnect the connector and clamp. (4WD Only) h) Reconnect the clamp. (2TR-FE Only) RH Side (4WD Only) RH Side (2TR-FE Only) 39. RECONNECT THE OIL COOLER TUBE (AUTO TRANS ONLY) a) Reconnect the oil cooler tube with the 2 bolts and torque to spec. Torque Spec: 28 N∙m (286 kgf∙cm, 21 ft∙lbf) Part # 17176-31130 NEW Replacement Parts Part Name Gasket, Air Surge Tank to Intake Manifold Kit # Qty 5 1 40. REINSTALL THE INTAKE AIR SURGE TANK (2GR-FKS ONLY) a) Install a NEW gasket onto the intake air surge tank. b) Reinstall the intake air surge tank with the 5 bolts and torque to spec. Torque Spec: 21 N∙m (214 kgf∙cm, 15 ft∙lbf) c) Reinstall the 2 intake air surge tank nuts and torque to spec. Torque Spec: 21 N∙m (214 kgf∙cm, 15 ft∙lbf) d) Reinstall the 2 surge tank stays with the 4 bolts, then torque to spec. Torque Spec: 21 N∙m (214 kgf∙cm, 15 ft∙lbf) e) Reinstall the throttle body bracket with the 2 bolts, then torque to spec. Torque Spec: 21 N∙m (214 kgf∙cm, 15 ft∙lbf) f) Reconnect the 2 wire harness clamps and hose clamp. g) Reconnect the throttle body w/ motor connector. h) Reconnect the 2 water by-pass hoses. i) Reconnect the PCV hose. j) Reconnect the intake air control valve connector. 56 41. REINSTALL THE INTAKE AIR CONNECTOR (2TR-FE ONLY) a) Reinstall the intake air connector with the 3 bolts, then torque to spec. Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf) b) Tighten the hose clamp bolts. Torque Spec: 5.0 N∙m (51 kgf∙cm, 44 in∙lbf) c) Reconnect the vacuum hose. d) Reconnect the No.2 ventilation hose. e) Reconnect the vacuum hose. f) Reconnect the wire harness clamp. g) Reconnect the pressure sensor connector. 42. REINSTALL THE POWER STEERING PUMP ASSY a) Reinstall the bolt and reconnect the ground wire and torque to spec. (2GR-FKS Only) Torque Spec: 8.5 N∙m (87 kgf∙cm, 75 in∙lbf) b) Reinstall the power steering vane pump with the 2 bolts, then torque to spec. Torque Spec: 21 N∙m (214 kgf∙cm, 15 ft∙lbf) c) Reconnect the connector. 43. REINSTALL THE V-BELT 44. REINSTALL THE FUEL TANK STRAPS a) Part # 90119-A0249 NEW Replacement Parts Part Name Bolt Kit # 2 Qty 2 Reinstall the fuel tank straps with the 2 pins and 2 clips. 45. REINSTALL THE FUEL TANK a) Reinstall the fuel tank with the 2 NEW bolts and torque to spec. Torque Spec: 62 N∙m (632 kgf∙cm, 46 ft∙lbf) b) Reconnect the connector. 46. REINSTALL THE NO.2 FUEL TANK PROTECTOR (IF EQUIPPED) 47. REINSTALL THE NO.1 FUEL TANK PROTECTOR ASSY (IF EQUIPPED) Part # 90179-08241 NEW Replacement Parts Part Name Nut *Individual Part(s) Kit # NA* Qty 4 a) Reinstall the No.1 fuel tank protector assy with the 4 NEW nuts and torque to spec. Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf) 57 Part # 77285-04100 90105-A0066 Part # 17451-0D060 90917-06083 NEW Replacement Parts Part Name Clamp, Fuel Tube, No.1 Bolt *Individual Part(s) NEW Replacement Parts Part Name Gasket, Exhaust Pipe Gasket, Exhaust Pipe, No.2 Kit # NA* NA* Qty 1 1 Kit # 5 NA* Qty 1 1 Kit # 5 5 5 Qty 2 2 2 49. REINSTALL THE EXHAUST SYSTEM (2GR-FKS ONLY) *Individual Part(s) Part # 90080-10064 90080-10291 90501-A0031 NEW Replacement Parts Part Name Bolt Bolt Spring 48. REINSTALL THE CHARCOAL CANISTER ASSY a) Reinstall the charcoal canister assy with the bolt and 2 nuts, then torque to spec. Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf) b) Reconnect the 2 fuel tank vent hoses. c) Reconnect the fuel hose. d) Install the NEW clamp. e) Reconnect the connector. f) w/ Rear Differential Lock: Install the NEW bolt and connect the skid control sensor wire bracket and torque to spec. w/o Rear Differential Lock: Install the bolt and reconnect the skid control sensor wire bracket and torque to spec. Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf) a) b) Reconnect the exhaust pipe support to the frame. Install the 2 NEW exhaust pipe gaskets. c) Reconnect the 5 exhaust pipe supports to the frame and reinstall the center exhaust pipe assy. Install the 2 NEW bolts and 2 NEW springs, then torque to spec. d) Torque Spec: 43 N∙m (438 kgf∙cm, 32 ft∙lbf) e) Install the 2 NEW bolts and 2 nuts, then torque to spec. Torque Spec: 48 N∙m (489 kgf∙cm, 35 ft∙lbf) 58 50. REINSTALL THE EXHAUST SYSTEM (2TR-FE ONLY) a) Reconnect the exhaust pipe support to the frame. b) Reconnect the 2 oxygen sensor wire harness clamps. NEW Replacement Parts c) Install the NEW exhaust pipe gasket. Part # Part Name Kit # Qty d) Reconnect the 4 exhaust pipe supports to the frame and 90080-10064 Bolt 6 2 reinstall the center exhaust pipe assy. 90080-43033 Gasket 6 1 e) Install the 2 NEW bolts and 2 NEW nuts, then torque to 90177-A0004 Nut 6 2 spec. Torque Spec: 48 N∙m (489 kgf∙cm, 35 ft∙lbf) 51. REINSTALL THE EXHAUST PIPE STOPPER BRACKET (IF EQUIPPED) Part # 90080-11180 NEW Replacement Parts Part Name Bolt Kit # 5 Qty 2 Part # 90119-A0169 NEW Replacement Parts Part Name Bolt Kit # 9 Qty 2 a) Reinstall the exhaust pipe stopper bracket with the 2 NEW bolts and torque to spec. Torque Spec: 19 N∙m (194 kgf∙cm, 14 ft∙lbf) 52. REINSTALL THE BRAKE TUBE HEAT INSULATOR (IF EQUIPPED) a) Reinstall the brake tube heat insulator with the 2 NEW bolts and torque to spec. Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf) 53. REINSTALL THE REAR PROPELLER SHAFT ASSY a) Referencing the matchmarks, reinstall the propeller shaft assy to the transmission / transfer case. b) Reinstall the 4 washers and 4 nuts, then torque to spec. Torque Spec: 88.2 N∙m (899 kgf∙cm, 65 ft∙lbf) c) Reinstall the center support bearing to the frame as shown in the illustration with 2 washer and 2 bolts, then torque to spec. (3-Joint Type Only) Torque Spec: 36.2 N∙m (369 kgf∙cm, 27 ft∙lbf) d) Referencing the matchmarks, reinstall the propeller shaft assy to the rear differential with 4 bolts, 4 washers and 4 nuts, then torque to spec. Torque Spec: 88.2 N∙m (899 kgf∙cm, 65 ft∙lbf) 54. RECONNECT THE FRONT PROPELLER SHAFT ASSY (4WD ONLY) a) Referencing the matchmarks, reconnect the front propeller shaft assy to the transfer case and the front differential with 4 bolts, 4 washers and 4 nuts, then torque to spec. Torque Spec: 88.2 N∙m (899 kgf∙cm, 65 ft∙lbf) 55. REMOVE THE FRAME FROM THE LIFT a) Remove the ratcheting tie down strap from the frame. b) Lower the frame to the ground. 59 I. REINSTALL THE CAB BODY ASSY Before lowering the cab assembly ensure that you install the NEW brakelines onto the bulk head. Part # 47313-04250 47313-04260 47315-04171 47315-04200 47323-04200 47323-04210 47324-04160 47324-04170 NEW Replacement Parts Part Name Tube, Front Brake, No.3** Tube, Front Brake, No.5** Tube, Rear Brake, No.3** Tube, Rear Brake, No.4** Kit # NA* 8 8 NA* NA* 8 NA* 8 Qty 1 1 1 1 1 1 1 1 *Individual Part(s) **Only 1 part used, part number varies by vehicle type. 2. 1. INSTALL THE NEW ENGINE COMPARTMENT BRAKE TUBES a) Install the NEW No.3 and NEW No.5 front brake tubes. b) Install the NEW No.3 and NEW No.4 rear brake tubes. c) Torque all brake tubes to spec. Torque Spec: Flare Nut (M10) - 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf) Flare Nut (M12) - 19.5 N∙m (199 kgf∙cm, 14 ft∙lbf) REINSTALL THE CAB BODY ASSEMBLY a) b) c) d) e) Raise the cab assy high enough so that the top of the engine clears the lowest point of the cab. Push the frame under the cab assy and line the tires up with the alignment marks. Lower the cab assy slowly, making sure it does not interfere with anything. Adjust the vehicle’s frame as needed to align the cab mounts with the cab assy bolts. Once the cab assy is set on the mounts, secure it to the frame with 6 bolts, 6 nuts, 6 washers and torque to spec. Torque Spec: No.1 - 37.5 N∙m (382 kgf∙cm, 28 ft∙lbf) No.2, No.3 - 45 N∙m (459 kgf∙cm, 33 ft∙lbf) f) Reinstall the 4 hole plugs. NOTE: • DO NOT work directly underneath the vehicle when pushing the frame under the cab assy. • Slowly lower the cab assy making sure the wire harness, steering shaft & hoses don’t interfere. • With 2 to 3 people checking for interference, slowly lower the cab body assembly to the frame. 60 NEW Replacement Parts Part # Part Name 90119-A0169 Bolt 90412-10276 Way, No.2 (For Rear Brake Tube) Kit # 9 2 Qty 1 1 3. RECONNECT THE PARKING BRAKE CABLE 4. CONNECT THE REAR BRAKE TUBES a) Temporarily install the NEW 2 way with the NEW bolt. b) Temporarily install the 4 rear brake tubes. c) Torque the bolt to spec. Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf) d) Torque the 4 rear brake tubes to spec. Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf) 5. RECONNECT THE FUEL TANK TUBES a) b) 6. RECONNECT THE NO.2 FUEL HOSE a) 7. Reconnect the 2 fuel tank tubes. Reinstall the fuel pipe clamp. NOTE: • Align the connector with the pipe, and push into the connector until the connector makes a "click" sound. If the connection is tight, apply a little amount of fresh engine oil on the tip of the pipe. • Ensure the pipe and the connector are securely connected by pulling them. Reconnect the No.2 fuel hose with the clip. RECONNECT THE SHIFT CABLE (AUTO TRANS ONLY) a) Reconnect the shift cable with the nut and torque to spec. Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft∙lbf) b) Reinstall the clip. 61 8. CONNECT THE CLUTCH RELEASE CYLINDER ASSY (2TR-FE MANUAL TRANS ONLY) a) Reconnect the clutch release cylinder with the 2 bolts and torque to spec. Torque Spec: 11.8 N∙m (120 kgf∙cm, 9 ft∙lbf) b) Reconnect the clutch hose with the bolt and torque to spec. Torque Spec: 37 N∙m (377 kgf∙cm, 27 ft∙lbf) 9. RECONNECT THE NO.1 CLUTCH HOSE (2GR-FKS MANUAL TRANS ONLY) a) b) Reconnect the clutch hose with the clip. Reconnect the clutch release cylinder tube to the clutch hose. Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf) Part # 90080-11555 NEW Replacement Parts Part Name Bolt LH Side 10. RECONNECT THE STEERING SLIDING YOKE Kit # 2 Qty 2 a) Make sure the front wheels are in a straight-ahead position and the steering wheel is centered. b) Referencing the matchmarks, connect the steering sliding yoke to the control valve shaft with the NEW bolt (B). c) Remove bolt (A) and install the NEW bolt (A). d) Torque all bolts to spec. Torque Spec: 35 N∙m (357 kgf∙cm, 26 ft∙lbf) e) Disconnect the seat belt that is holding the steering wheel. 11. RECONNECT THE FRONT SKID CONTROL SENSOR WIRE HARNESS a) b) Reconnect the harness clamp and front skid control sensor connector. Repeat the procedure on the opposite side. RH Side 12. RECONNECT THE NO.2 FRAME WIRE HARNESS (IF EQUIPPED) a) Reconnect the harness clamp and connector. 62 LH Side 13. RECONNECT THE FRONT BRAKE TUBES a) Reconnect the front brake tube and torque to spec. Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf) b) Repeat the procedure on the opposite side. RH Side Part # 90210-A0002 NEW Replacement Parts Part Name O Ring Kit # 2 Qty 1 14. RECONNECT THE AIR CONDITIONING DISCHARGE HOSE TO THE COMPRESSOR a) b) Install a NEW o-ring to the A/C discharge hose. Reconnect the A/C discharge hose to the compressor, then torque to spec. Torque Spec: 19 N∙m (194 kgf∙cm, 14 ft∙lbf) Part # 90301-A0006 NEW Replacement Parts Part Name O Ring 2TR-FE Kit # 2 Qty 2 15. RECONNECT THE SUCTION HOSE TO THE AIR CONDITIONING UNIT ASSY a) b) Install the 2 NEW o-rings to the suction hose. Reconnect the cooler bracket with the bolts and torque to spec. Torque Spec: 7.5 N∙m (76 kgf∙cm, 66 in∙lbf) c) Reconnect the suction hose and piping clamp. NOTE: Check that the claw of the piping clamp is correctly fitted. 2GR-FKS 63 LH Side 16. REINSTALL THE FRONT FENDER APRON SEAL a) Reinstall the 4 front fender apron seals with the 20 clips. RH Side 17. RECONNECT THE WATER / HEATER HOSES, ENGINE SIDE (2GR-FKS ONLY) 18. RECONNECT THE WATER / HEATER HOSES, HEATER RADIATOR SIDE (2TR-FE ONLY) 19. RECONNECT THE ENGINE WIRE HARNESS a) b) Reinstall the engine wire harness container to the cowl panel. Reconnect the clamp. 20. RECONNECT THE NO.1 HOSE (2TR-FE ONLY) a) Reconnect the No.1 hose. 21. RECONNECT THE POWER STEERING PUMP OIL RESERVOIR ASSY (2GR-FKS ONLY) a) Reconnect the power steering pump oil reservoir assy. 64 22. REINSTALL THE FAN SHROUD Part # 16442-0C420 NEW Replacement Parts Part Name Packing 23. REINSTALL THE RADIATOR ASSY Kit # 2 Qty 1 a) Install the NEW o-ring to the drain plug. b) Tighten the radiator drain plug. c) Reinstall the radiator with 4 bolts and torque to spec. Torque Spec: 18 N∙m (184 kgf∙cm, 13 ft∙lbf) d) Reinstall the automatic transmission cooler lines (Auto Trans Only). e) Reinstall the fan shroud with the 2 bolts. Torque Spec: 6.0 N∙m (61 kgf∙cm, 53 in∙lbf) ･Do not remove the radiator side deflectors. ･Be careful not to over-flex the deflectors when reinstalling the radiator assy. 24. RECONNECT THE RADIATOR HOSES 25. REINSTALL THE RADIATOR SUPPORT TO FRAME SEAL 2TR-FE 26. RECONNECT THE VACUUM HOSE a) Reconnect the vacuum hose. 2GR-FKS 27. RECONNECT THE FUEL PIPES a) b) Reconnect the 2 fuel pipes. Reinstall the fuel pipe clamps. NOTE: • Align the connector with the pipe, and push into the connector until the connector makes a "click" sound. If the connection is tight, apply a little amount of fresh engine oil on the tip of the pipe. • Ensure the pipe and the connector are securely connected by pulling them. 28. RECONNECT THE FUEL VAPOR FEED HOSE 65 29. RECONNECT THE FRONT DIFFERENTIAL BREATHER TUBES (4WD ONLY) a) Reconnect the front differential breather tubes. 30. RECONNECT THE NO.2 ENGINE WIRE HARNESS a) b) Remove the No.1 upper relay block cover. Reconnect the 5 connectors. NOTE: The number of connectors may differ depending on the model. c) Reinstall fuse box wire harness with the nut and torque to spec. Torque Spec: 8.5 N∙m (87 kgf∙cm, 75 ft∙lbf) d) Reinstall the 2 clamps. e) Reinstall the No.1 upper relay block cover. f) g) Reconnect the connector. Reconnect the No.2 engine wire harness to the clamp. NOTE: The number of clamps may differ depending on the model. h) Reinstall the (+) positive battery cable with the nut and torque to spec. Torque Spec: 7.6 N∙m (77 kgf∙cm, 67 in∙lbf) i) Reinstall the ground wire with the bolt and torque to spec. Torque Spec: 8.5 N∙m (87 kgf∙cm, 75 in∙lbf) 31. REINSTALL THE FOLLOWING PARTS • Air Cleaner Hose and Air Cleaner Assy Torque Spec: 12 N∙m (122 kgf∙cm, 9 ft∙lbf) • V-Bank Cover 32. REINSTALL THE FOLLOWING PARTS (ACCESS CAB ONLY) • Rear Floor Side Service Hole Cover LH/RH • Seat Floor Box • Floor Board No.1/No.2 • Rear Seat Cushion Assy • Rear Lower Console Box 33. RECONNECT THE PARKING BRAKE CABLES a) Reconnect the 2 parking brake cables. b) Adjust parking brake lever travel. c) Reinstall the parking cable end stopper. 66 34. REINSTALL THE FOLLOWING PARTS • Manual Transmission Shift Lever (Manual Trans Only) • Voltage Inverter Assy (If Equipped) • Rear Console Box 35. RECONNECT THE ENGINE WIRE HARNESS a) Reconnect each connector and clamp to the ECM and engine wire harness. NOTE: The number of connectors may differ depending on the model. 36. REINSTALL THE FOLLOWING PARTS • Instrument Lower Panel Assy • Lower No.2 Instrument Panel Airbag Assy Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) • Glove Compartment Plate • • • • Instrument Side Panel LH Front Floor Footrest Cowl Side Trim Board LH/RH Front Door Scuff Plate LH/RH 37. RECONNECT THE NO.2 FRAME WIRE HARNESS (IF EQUIPPED) Part # 90119-A0148 NEW Replacement Parts Part Name Bolt *Individual Part(s) Kit # NA* Qty 2 a) Reconnect the 2 connectors and clamp. b) Reinstall the wiring harness protector cover with the 2 NEW bolts and torque to spec. Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf) 38. REINSTALL THE FOLLOWING PARTS NEW Replacement Parts Front No.2 Bumper Extension Sub-Assy LH/RH Part # Part Name Kit # Qty 90178-A0044 Nut 2 6 • Front No.2 Bumper Extension Sub-Assy LH/RH Reinstall the No.2 front bumper extension with 6 NEW nuts and torque to spec. Torque Spec: 58 N∙m (591 kgf∙cm, 43 ft∙lbf) • Front Bumper Reinforcement Reinstall the front bumper reinforcement with 6 nuts and torque to spec. Torque Spec: 58 N∙m (591 kgf∙cm, 43 ft∙lbf) • Front Bumper Assy Reinstall the 8 clips. Reinstall with the 2 bolts, 4 screws and torque to spec. Torque Spec: Bolt - 5.0 N∙m (51 kgf∙cm, 44 in∙lbf) Screw - 2.8 N∙m (29 kgf∙cm, 25 in∙lbf) Reinstall the 2 screws. (Over Fender Only) • Radiator Grille 67 NEW Replacement Parts Part # 53851-04100 53853-04070 53855-04010 75395-35070 75396-35020 Moulding Part Name Pad, Front Wheel Opening Extension Pad, Front Wheel Opening Extension, No.1 Pad, Front Wheel Opening Extension, No.2 Clip, Outside Moulding, No.1 Clip, Outside Moulding, No.2 Kit # Qty 7 2 7 2 7 2 7 7 6 12 39. REINSTALL THE FRONT FENDER WHEEL OPENING MOULDING LH/RH (IF EQUIPPED) a) Click the link below to access TIS for instructions 2016 - 2017 a) b) When the clip installation part of the moulding is broken you should… (1) Clean and degrease the clip installation part. (2) Fill the clip installation part with adhesive. (3) Install the NEW clip. (4) Remove the extra adhesive. NOTE: If the extra adhesive is not removed, the moulding may not fit the vehicle body. (5) Install the moulding to vehicle body before the adhesive becomes solid. NOTE: If the moulding is installed after the adhesive became solid, clips may not engage the holes of the body. c) Engage the 3 claws and 9 clips to install the front fender wheel opening moulding. d) Install the 7 screws. NOTE: The number of screws may differ depending on the model. 40. REINSTALL THE FRONT FENDER MUDGUARD LH/RH (IF EQUIPPED) 68 J. REINSTALL THE BED ASSY 1. 2. REINSTALL THE BED ASSY a) Using a Torx® T55H Socket, reinstall the bed assy Torx ® bolts and torque to spec. Torque Spec: 60 N∙m (612 kgf∙cm, 44 ft∙lbf) NOTE: • Use 4 or more people to lift the bed assy. • Evenly support the bed assy when reinstalling it. • Be careful not to damage or hit the fuel inlet pipe when reinstalling the bed assy. • Protect the front side of the bed assy to not damage the cab assy. REINSTALL THE FUEL INLET PIPE SUB-ASSY a) Reinstall the fuel inlet pipe sub-assy with the bolt and torque to spec. Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf) NEW Replacement Parts Part # 75395-35070 75396-35020 75696-04050 75697-04050 75698-04030 90189-A0002 Moulding Part Name Clip, Outside Moulding, No.1 Clip, Outside Moulding, No.2 Pad, Body Outside Moulding, No.1 Pad, Body Outside Moulding, No.2 Pad, Body Outside Moulding, No.3 Clip Kit # 7 7 Qty 3 7 7 1 7 1 7 1 7 6 3. RECONNECT THE LEFT REAR WHEEL WELL LINER a) Install the left rear wheel well liner with the 8 clips and 3 screws. 4. REINSTALL THE QUARTER PANEL WHEEL OPENING MOULDING LH(IF EQUIPPED) a) Click the link below to access TIS for instructions 2016 - 2017 b) When the clip installation part of the moulding is broken you should… (1) Clean and degrease the clip installation part. (2) Fill the clip installation part with adhesive. (3) Install the NEW clip. (4) Remove the extra adhesive. NOTE: If the extra adhesive is not removed, the moulding may not fit the vehicle body. (5) Install the moulding to vehicle body before the adhesive becomes solid. NOTE: If the moulding is installed after the adhesive became solid, clips may not engage the holes of the body. c) Engage the 10 clips to install the quarter panel wheel opening moulding. d) Install the 7 screws. NOTE: The number of screws may differ depending on the model. 69 5. RECONNECT THE FRAME WIRE HARNESS a) 6. NEW Replacement Parts Part # 90119-A0192 Rear Bumper Assy Part Name Bolt *Individual Part(s) Kit # 2 NA* Qty 6 4 Reconnect the 6 wire harness clamps to the bed assy. NOTE: • The number of connectors will differ depending on the vehicle spec. • Use new clamps if the original ones are damaged. REINSTALL THE FOLLOWING PARTS • Power Outlet Socket Assy (If Equipped) • Side Step Assy LH/RH (If Equipped) • Rear Mudguard LH/RH (If Equipped) • Rear Bumper Assy Reinstall the rear bumper assy with the 10 NEW bolts and torque to spec. (Trailer Hitch Equipped Only) Reinstall the rear bumper assy with the 6 NEW bolts and torque to spec. Torque Spec: 90 N∙m (918 kgf∙cm, 66 ft∙lbf) • Rear Tail/Combination Light LH/RH 70 1. K. FINAL ASSEMBLY REINSTALL THE NEGATIVE (-) BATTERY TERMINAL 2. NEW Replacement Parts Part # 12157-10010 90430-24003 Front Differential Part Name Gasket, Front Differential Filler Plug Gasket, Front Differential Drain Plug Kit # Qty 3 1 3 1 Release Cylinder Heat Insulator Part Name Kit # Insulator, Release Cylinder 31461-35030 NA* Heat 90119-A0165 Bolt NA* *Individual Part(s) Part # Qty 1 4 REFILL THE FOLLOWING FLUIDS • Brake Fluid Remove the brake tubes from the master cylinder. Refill with Toyota Dot 3 Brake Fluid. Bleed the master cylinder. Reinstall the brake tubes to the master cylinder and torque to spec. Torque Spec: 19.5 N∙m (199 kgf∙cm, 14 ft∙lbf) Refill with Toyota Dot 3 Brake Fluid. Bleed the brake system at each wheel and torque the bleeder screws to spec. Torque Spec: 10.8 N∙m (110 kgf∙cm, 8 ft∙lbf) • Clutch Fluid (2GR-FKS Manual Trans Only) Refill with Toyota Dot 3 Brake Fluid. Bleed the clutch system and torque the bleeder screws to spec. Torque Spec: 11 N∙m (112 kgf∙cm, 8 ft∙lbf) • Release cylinder heat insulator (2GR-FKS Manual Trans Only) Install the NEW release cylinder heat insulator to the manual transmission assembly with the 4 NEW bolts. Torque Spec: 11.8 N∙m (120 kgf∙cm, 9 ft∙lbf) NOTE: 2TR Manual Transmission uses master cylinder reservoir for clutch. • Coolant Refill with Toyota Long Life Coolant. Bleed the cooling system. • Front Differential Fluid Install the NEW drain plug washer and torque to spec. Torque Spec: 64.7 N·m (660 kgf·cm, 48 ft·lbf) Refill with Hypoid Gear Oil API GL-5 75W-90. Install the NEW filler plug washer and torque to spec. Torque Spec: 39.2 N·m (400 kgf·cm, 29 ft·lbf) 3. 4. 5. START THE VEHICLE AND INSPECT THE FOLLOWING FOR LEAKS • Fuel System Start the engine and let it run for 5 seconds, then stop the engine and inspect for leaks. If there are no leaks, restart the engine and re-inspect. • Cooling System • Brake System • Clutch System (2GR-FKS Manual Trans Only) • Front Differential System RECHARGE THE A/C SYSTEM AND CHECK FOR PROPER OPERATION AND REFRIGERANT LEAKS CHECK THE OPERATION OF THE FOLLOWING SYSTEMS AND ADJUST AS NEEDED Make sure to follow the procedure outlined in the appropriate repair manual for the vehicle you are working on when checking, and if needed, adjusting the operation of the systems listed below. This is an important step, and must be performed thoroughly to ensure proper operation of these systems. • Parking Brake Travel • Shift Control Lever (Automatic Trans Only) • Clutch Pedal (Manual Trans Only) 71 6. CHECK ALL FLUID LEVELS AND ADJUST AS NEEDED Part # 43514-28010 95381-04045 NEW Replacement Parts Part Name Cap, Front Axle Hub Grease, LH/RH Cotter Pin Kit # Qty 3 2 3 2 7. TORQUE THE FRONT AXLE NUT (4WD ONLY) a) Remove the front wheels. b) Torque the front axle nut to spec. Torque Spec: 235 N∙m (2396 kgf∙cm, 173 ft∙lb) c) Reinstall the lock cap with the NEW cotter pin. d) Reinstall the NEW grease cap. e) Repeat the procedure on the opposite side. f) Reinstall the front wheels and torque to spec. Torque Spec: 113 N∙m (1152 kgf∙cm, 83 ft∙lbf) NOTE: If the holes for the cotter pin are not aligned, tighten the axle nut further, up to 60°. 8. PERFORM A WHEEL ALIGNMENT 9. CHECK THE HEADLIGHT AIM AND ADJUST AS NEEDED 10. REINSTALL THE ENGINE UNDER COVERS Part # 90080-11373 NEW Replacement Parts Part Name Bolt a) Kit # 7 Qty 8 Reinstall the engine under cover with 8 NEW bolts and torque to spec. Torque Spec: 30 N∙m (306 kgf∙cm, 22 ft∙lbf) 11. REINSTALL THE NO.1 WHEEL OPENING EXTENSION PAD (IF EQUIPPED) 12. CHECK FOR DTC’S AND REPAIR AS NEEDED 13. PERFORM INITIALIZATION 14. PERFORM BLIND SPOT MONITOR OPERATION CHECK b) Click the link below to access TIS for instructions 2016 2017 15. FINAL INSPECTION a) Check the operation of the following systems: • 4WD System (4WD Only) • Interior Lights • Exterior Lights • HVAC System • Audio System • • • • • Power Windows Power Door Locks Airbag System All Gauges, Indicators and Warning Lights Etc. 16. TEST DRIVE THE VEHICLE AND DOCUMENT FINAL REPAIR STATUS a) Test drive the vehicle and perform final repair sign off with the Frame Replacement Inspection Sheet. This must be performed and signed off by an MDT, Shop Foreman or Service Manager and retained with Final R.O. 72 APPENDIX As required by Federal Regulations, please make sure all recalled parts (original parts) removed from the vehicle are disposed of in a manner in which they will not be reused. Adequate time has been provided in the repair time to cut up and dispose of the perforated frame. 73 74 75